Can Base Die Support for Self-Aligning Dome Forming
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Solution Overview
Problem
The existing can bodymakers face challenges in accurately aligning the dome station with the punch, leading to misalignments that result in defects such as 'smile marks', 'local thinning', and 'split domes', which are difficult to maintain, especially during large batch runs and can cause quality issues that may not be immediately visible but lead to can bursting after filling.
Innovation Solution
The apparatus and method incorporate a resilient support for the die and a hold down ring that are deflectable perpendicular to the axis, allowing for a restoring force to maintain alignment, combined with eddy current sensors for precise measurement and an adjustment mechanism with linear actuators and locking mechanisms to facilitate easy alignment and realignment, reducing the sensitivity to misalignments and enabling efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the dome station is aligned statically when the machine is not running, then initial alignment can be achieved, but misalignment occurs during running due to dynamic effects
Solution Approach 1:
The patent applies the dynamics principle by making the die support movable rather than fixed. The die support is configured to move automatically in response to punch misalignment, allowing the system to adapt dynamically during operation. This resolves the contradiction by enabling the alignment system to maintain precision while accommodating dynamic effects during machine running.
Solution Approach 2:
The die support performs self-alignment by automatically moving in response to punch position variations. The resilient means enables the die support to self-correct its position without external intervention, maintaining alignment precision during dynamic operation while eliminating the need for continuous manual adjustment.
2Manufacturing precision
If traditional alignment methods are used, then alignment can be achieved, but the process is time consuming and requires halting the production line
Solution Approach 1:
The die support with resilient means performs automatic self-alignment during machine operation without requiring production halt. This eliminates time-consuming manual alignment procedures while maintaining precise alignment, thereby resolving the contradiction between alignment precision and production efficiency.
Solution Approach 2:
The alignment mechanism operates continuously during machine running rather than requiring periodic shutdowns. The resilient die support continuously adapts to punch position variations, ensuring uninterrupted production while maintaining alignment precision throughout the process.
3Stability of the object's composition
If the die is fixed rigidly, then structural stability is maintained, but sensitivity to misalignment increases causing defects
Solution Approach 1:
The patent replaces the rigid fixed die support with a movable die support supported by resilient means. This dynamic configuration allows the die support to move and adapt to punch misalignment, reducing sensitivity to misalignment while maintaining structural stability through the resilient support mechanism.
Solution Approach 2:
The resilient means changes the mechanical parameters of the die support system by introducing elasticity and movement capability. This allows the die support to adjust its position dynamically, reducing misalignment sensitivity while maintaining overall structural stability during the forming process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the sensitivity to misalignments, allowing for easier and more precise alignment of the dome station, minimizing defects and maintaining high-quality can production while reducing downtime and operational costs by allowing for continuous operation without halting the production line.
Implementation Method 1
a resilient support for holding the die in a resting position substantially along said axis whilst allowing the die to be deflectable perpendicular to said axis and providing a restoring force to return the die to the resting position
Implementation Method 2
The sensors may be eddy current sensors
Data Source
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AI summary
An apparatus (100) for forming a base profile on a metal container carried on a punch moving along an axis. The apparatus comprises a die (105) for forming the base profile on the container and a resilient support for holding the die (105) in a resting position substantially along said axis whilst allowing the die (105) to be deflectable perpendicular to said axis and providing a restoring force to return the die (105) to the resting position.